Structured Light Projection System Optical Axis Alignment
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Solution Overview
Problem
Existing structured light projection systems face challenges in precise optical axis alignment, leading to reduced resolution and increased production costs due to the complexity of combining multiple optical lenses with different refractive powers, which affects yield and stability.
Innovation Solution
A structured light projection system is designed with a primary optics packaging method where the first optical module is directly molded onto the semiconductor laser chip, eliminating air gaps and simplifying optical axis alignment, and the second optical module includes a diffractive optical element, reducing deviation and increasing yield through coaxial alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple optical lenses with different refractive powers are combined and overlapping to form a conversion lens module, then the optical conversion function is improved, but the device complexity and manufacturing difficulty increase significantly
Solution Approach 1:
The patent combines multiple optical lenses with different refractive powers into a single integrated conversion lens module, where the lenses are arranged in specific intervals and overlapping configurations. This merging approach maintains the complex optical conversion functionality while reducing the number of separate components and alignment steps required in the manufacturing process.
2Measurement precision
If multiple optical lenses are precisely aligned to maintain optical axis coincidence, then the measurement precision and resolution are improved, but the manufacturing time and cost increase
Solution Approach 1:
The patent employs preliminary action by pre-aligning the optical axes of multiple lenses during the module assembly process and fixing their relative positions at specific intervals. This preliminary alignment ensures that the optical axes remain coincident during subsequent manufacturing and usage, eliminating the need for repeated precise calibration and reducing overall production time.
3Volume of moving object
If the number of optical lens layers is increased to achieve thinning effect, then the compactness is improved, but the optical axis alignment deviation accumulates and yield decreases
Solution Approach 1:
The patent applies the nested doll principle by arranging multiple optical lenses in a compact, overlapping configuration where lenses are positioned at specific intervals and partially overlap each other. This nesting approach achieves space efficiency and thinning while maintaining controlled optical axis alignment through the designed overlapping structure, preventing cumulative deviation.
4Productivity
If wafer lens packaging process is used for manufacturing structured light projector, then the production efficiency is improved, but the manufacturing cost and design complexity increase
Solution Approach 1:
The patent segments the optical system into distinct functional modules: a laser module, a beam expanding module with conversion lens, and a structured light generation module with DOE. This segmentation allows each module to be manufactured and optimized independently using appropriate processes, avoiding the need for costly wafer-level packaging while maintaining high production efficiency through modular assembly.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This design enhances precision and yield by minimizing optical axis deviation and reducing manufacturing costs, while allowing for more precise and flexible optical design without the need for costly wafer level optics processes.
Implementation Method 1
at least one semiconductor laser chip electrically connected on the installation surface of the substrate and configured to generate at least one beam
Implementation Method 2
the first optical module is composed of at least one optical lens; further, the second optical module is disposed on the first optical module, and the second optical module includes a case and at least one diffractive optical element
Implementation Method 3
the second optical module includes a case and at least one diffractive optical element
Data Source
AI summary
A structured light projection system including a substrate, a semiconductor laser chip, a first optical module, and a second optical module is provided. The semiconductor laser chip is electrically connected to the substrate. The first optical module is disposed on the substrate. The second optical module is disposed on the first optical module. The deviation rate between optical axes of the optical modules and the semiconductor laser chip and the calibration time thereof are reduced by the first optical module directly packaging the substrate through a primary optics design, so as to increase the yield of the structured light projection.